Milling system and method

ABSTRACT

A milling system for milling patterns into a workpiece is disclosed. The system comprises a baseplate having an aperture and a template disposed within the aperture and positionable in a plurality of registrated orientations relative to the baseplate. The baseplate is formed of two separable baseplate parts. A system for vertically supporting a rotary cutting tool is also disclosed. The system comprises a base, a plurality of posts extending upwardly from the base, and a tool support for supporting the rotary tool. The tool support has a plurality of sleeves, one associated with each of the posts. The sleeves slidably receive respective ones of the posts. The tool support further includes springs for biasing the tool support away from the base.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority of U.S. provisional patentapplication, serial No. 60/344,570, filed Nov. 9, 2001.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable.

BACKGROUND OF THE INVENTION

[0003] The invention pertains to a device in the form of a millingsystem 12 associated with a method for the milling of simple up tocomplex, complementary and expandable patterns from a workpiece 7 bymeans of a router 11 with tracing collar 16 and router bit 17. Themilling system 12 has a base plate 2 and a movable template 3 thatcontains sectors 8 with pattern cutouts (examples) 4 in definedpositions.

[0004] By shifting, turning, and rotating the parts of the millingsystem 12 after each milling process, particularly the movable template3, several of the pattern cutouts (example) 4 in the template 3 can beused to mill out a great number of pattern combinations and patternvariations.

[0005] The milling of complementary patterns is also possible, since thepattern to be milled can be broken down in accordance with a definedsystem and cut out with the pattern cutouts (example) 4 of the movabletemplate 3.

[0006] Different templates are compatible and can complement each otherto form new patterns. Due to the use of a guide bar 13, several patternsto be milled can be expanded in the X-direction and in the Y-direction.

[0007] The invention pertains to a device in the form of a millingsystem, associated with a method for milling simple to complex,complementary and expandable patterns from a workpiece by means of arouter 11 with tracing collar 16 and router bit 17 according to thepreamble of claim 1. A pattern can be understood as the following:shapes, images, symbols, letters, numbers, ornaments in the manner ofchip carvings, decorations, etc.

[0008] Using milling systems when routing or inlay-milling a widevariety of patterns with the aid of hand router is known. Thesetemplates are used as interior and exterior templates. A template mustbe made for each pattern to be milled. The milling process then runs asfollows. The template is affixed to the workpiece. Then by means of astop collar attached to the hand router, the contours of the templateare traced (for exterior templates: tracing of the template's exteriorcontour; for interior templates: tracing of the template's interiorcontour). More complex milling work is possible with the aid of a CNCmilling machine (computer-controlled NC machine).

[0009] Known milling systems (interior templates, exterior templates)have the disadvantage that a separate milling system must be created foreach pattern to be milled. With these templates, only the one designatedpattern can be milled. This applies to the exterior templates as well asto the interior templates. The production of such templates is verytime-consuming and expensive. Moreover, it requires, in addition to theappropriate manufacturing methods, a certain creativity and specialskills in the field of ornamentation of workpieces.

[0010] The quality of the milling depends directly on the execution ofthe template. Thus, uneven areas on the cutouts (for interior templates)and on the template periphery (for the exterior templates) aretransferred directly to the milling.

[0011] The disadvantage of exterior milling systems is that only theexterior perimeter of a pattern can be cut out. And the disadvantage ofinterior milling systems is that the complete milling of a complexpattern is not possible since not all details can be cut away from themilling system. This is due to the dropping out of certain partial zonesof the template due to a possibly unavoidable overcutting in the millingpass (for example, in a template for milling out the uppercase letterB). When using a router 11 with tracing collar 16 and router bit 17 andthe corresponding template, the undesirable overcutting problems appearin the middle milled region of the “B.” Another example of this problemis a template for milling several circles of different diameter about acommon center. Here, only the largest diameter could appear on thetemplate, since the smaller template sections would merely drop out.

[0012] More extensive pattern structures (for instance, a rose withpetals) can only be milled out with the aid of computerized NC machines(CNCs). For medium-scale woodworking shops, use of these computerized NCmachines is usually cost-prohibitive. In addition, such machines canonly be used in workshops. Due to their significant weight, they cannotbe used on-site. Moreover, as a rule, for reasons of cost, the use ofsuch NC machines is not possible by the nonprofessional hobbyist.

[0013] Therefore, the object of the present invention is a millingsystem, associated with a method for the milling of simple up to complexcomplementary and expandable patterns from a workpiece 7 by means of arouter 11 with tracing collar 16 and router bit 17, wherein a few basicpatterns in the form of pattern cutouts (examples) 4 are used to createa very large number of different pattern combinations and variants.

[0014] Additionally, when milling, it has been difficult to accuratelyand comfortably hold and control the milling tool.

SUMMARY OF THE INVENTION

[0015] According to the present invention, an object is realized by adevice associated with a method having the characteristics of claim 1.

[0016] The user of the router 11 with tracing collar 16 and router bit17 will be able, by means of the milling system 12 according to thepresent invention and the selection of only a few pattern cutouts(example) 4 at specified positions on the movable template 3, to createseveral different, complex, complete, complementary patterns whose shapeand size can be expanded indefinitely, merely by sliding, turning androtating the movable template 3 after each milling process. Thus, itwill be possible to mill from one to a significant number of patterncombinations, and also to mill pattern variations. The milling of carvedornamentation (notch cutting) is also possible. Due to an appropriateplacement of the pattern cutouts (example) 4 on the movable template 3,it is possible to expand the size of the pattern being cut (e.g., a rosewith petals, where additional outer, supplemental petals can be addedon). Partial milling of a pattern is also possible (e.g., ¼ or½-pattern) (FIG. 12).

[0017] Due to the use of additional, compatible templates and also of aguide bar 13 adjustable in the X-direction and in the Y-direction, thesize or shape of a pattern can also be varied.

[0018] This provides the user of this milling system with theopportunity to form milled patterns like those that are only possiblewith a CNC machine. The time-consuming, and thus expensive, productionof individual milling systems is now unnecessary for the user. If thehobbyist and recreational user is lacking in the required creativity andmilling experience, particularly in regard to ornamentation ofworkpieces, then by using this milling system, he can quickly and easilyform elegant patterns in workpieces.

[0019] An additional advantage over conventional milling systems is thatthe user now has the possibility of independently varying the pattern tobe cut. Furthermore, by breaking down the pattern to be milled into acorresponding number of basic patterns on the milling system in the formof pattern cutouts 4 in the movable template 3, the milling of complexand complete patterns is possible. In addition, due to this breakingdown of the subsequent milling process, any potentially undesirableovercutting during the course of the milling can be prevented (forexample, the letter ‘B’).

[0020] By means of an appropriate selection of the router bit 17 and ofthe tracing collar 16, the appearance of the milled pattern can bevaried once again. Insert and recess milling of patterns is possiblesimultaneously with this milling system 12. The milling systems aredesigned so that an expansion or complementation of patterns is possiblethrough the use of additional, compatible movable templates 3 equippedwith different pattern cutouts (example) 4, or through the use of aguide bar 13 which is adjustable both in the X-direction and theY-direction.

[0021] Therefore, the task of the invention concerns a versatile,easy-to-handle, low-cost, and expandable milling system which avoids thedisadvantages of known milling systems.

[0022] A preferred embodiment of the milling system of the invention andalso additional advantageous embodiment examples of the invention areillustrated in principle in the drawings and will be described below ingreater detail.

[0023] It is a further object of the invention to provide a millingsystem for milling patterns into a workpiece. The system comprises abaseplate having an aperture and a template disposed within theaperture. The template is positionable in a plurality of registratedorientations relative to the baseplate, wherein the baseplate is formedof two separable baseplate parts.

[0024] It is a still further object of the invention to provide a systemfor vertically supporting a rotary cutting tool. The system comprises abase, a plurality of posts extending upwardly from the base, and a toolsupport for supporting the rotary tool. The tool support has a pluralityof sleeves, one associated with each of the posts. The sleeves slidablyreceiving respective ones of the posts. The system further includesmeans for biasing the tool support away from the base.

[0025] These and other aspects and attributes of the present inventionwill be discussed with reference to the following drawings andaccompanying specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0026]FIG. 1, a perspective view of a preferred embodiment of themilling system according to the present invention, with fitted, movabletemplate and guide bar adjustable in the X-direction and Y-direction;

[0027]FIG. 2, a top view of a preferred embodiment of the milling systemaccording to the present invention, with examples of pattern cutouts inthe movable template;

[0028] FIGS. 3 to 8, a selection of combination milling patterns andvariants for the use of the sample pattern cutouts according to FIG. 2of the milling system according to the present invention, while stillusing the guide bar adjustable in the X-direction and Y-directionaccording to FIG. 1;

[0029]FIG. 9, a top view of an additional, preferred embodiment of themilling system according to the present invention, with additionalexamples of sample cutouts in the movable template;

[0030] FIGS. 10 to 15, a selection of milling pattern combinations andvariants for the use of the pattern cutout examples according to FIG. 9of the milling system according to the present invention;

[0031]FIG. 16, a top view of an additional embodiment of a millingsystem with movable template in a base plate and also an alternativelocking means;

[0032]FIG. 17, a top view of a milling system with movable template, inwhich, in turn, one or more movable templates are installed;

[0033]FIG. 18, a top view of a milling system with movable template, inwhich, in turn, one or more rectangular movable templates are installed,in which, again in turn, a movable template has been installed;

[0034]FIG. 19, a top view of a rectangular milling system with movable,rectangular template, in which, in turn, a movable template has beeninstalled;

[0035]FIG. 20, a top view of a milling system with movable, rectangulartemplate;

[0036]FIG. 21, a top view of an additional embodiment of a millingsystem with movable template in a base plate, and also an additional,alternative locking means;

[0037]FIG. 22 is a perspective view of a particular embodiment of amilling system according to the invention;

[0038]FIG. 23 is a perspective view of a baseplate of the milling systemof FIG. 22;

[0039]FIG. 24 is a perspective view of an upper side of a template ofthe milling system of FIG. 22;

[0040]FIG. 25 is a perspective view of a lower side of the template ofthe milling system of FIG. 22;

[0041]FIG. 25a is a perspective view of a pencil guide in accordancewith the invention;

[0042]FIG. 26 is a perspective view of a system for verticallysupporting a rotary tool in accordance with the invention;

[0043]FIG. 27 is a perspective view of a baseplate of the system of FIG.26;

[0044]FIG. 28 is a perspective view of a tool support of the system ofFIG. 26

[0045]FIG. 29 is a perspective view of the tool support of FIG. 28, fromits underside;

[0046]FIG. 30 is a perspective view of a guide bushing of the toolsupport of FIG. 29; and

[0047]FIG. 31 is a perspective view of a portion of a base of the toolsupport of FIG. 29.

DETAILED DESCRIPTION OF THE INVENTION

[0048] While this invention is susceptible of embodiment in manydifferent forms, there is shown in the drawing, and will be describedherein in detail, specific embodiments thereof with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit theinvention to the specific embodiments illustrated.

[0049] The preferred embodiment of the milling system according to thepresent invention (FIG. 1) consists of a base plate 2 and also at leastone movable template 3. The base plate can be made from, e.g., wood,aluminum, hard plastic, hard paper or another nondeformable material.The thickness of the base plate 2 and also the given template 3 shouldbe ideally about 2-20 mm, depending on application. In this regard, bothparts should have the same material thickness. In the preferredembodiment of the milling system according to the present invention, acutout 1 has been formed in the base plate 2 in order to hold themovable template 3. The movable template 3 in the preferred embodimentof the milling system according to the present invention is circular,and fits exactly into the circular cutout of the base plate 2 wheninserted. Alternatively, in an additional embodiment of the millingsystem according to the present invention, the movable template 3 can beformed as a polygon (FIG. 20). Accordingly, the base plate 2 will thenalso contain polygonal cutouts. A means for locking the plate in place(base plate/movable template) 9 is provided. This makes it possible tolock the movable template 3 for one milling pattern in a definedposition to the base plate 2. Depending on the pattern to be cut, themovable template 3 is divided into several same sectors 8 of the samesize. At least one pattern cutout (example) 4 is incorporated as acutout at one precisely defined area of the movable template 3. Theposition of the movable template 3 can be changed after each millingprocess, by sliding, turning, or rotating within the base plate 2. Thenumber of the pattern cutouts (example) 4 depends on the size of themovable template 3 and also on the complexity of the pattern to bemilled. In order to attain additional versatility in the pattern, aninsert 5 can be installed into a pattern cutout provided therefor.

[0050] The templates, in particular the movable template 3, are designedso that they are mutually compatible and will complement each other forthe cutting of new patterns. However, this only applies to templateswith the same-size template. In one particular refinement of the millingsystems according to the present invention, through the use of a guidebar 13 adjustable in the X- and Y-directions, an expansion of thepatterns is possible. On the base plate 2 of the milling systemaccording to the present invention, there is a means 10 provided forsecuring of this guide bar. The guide bar 13 can be locked in place, forexample, by use of a locking bolt 15. When this locking feature is used,the locking bolts 15 are inserted into the holes drilled for the lockingunit 14. The distance between the drilled holes for the locking unit 14is a defined value, in order to ensure the precise movement of themilling system in the X- or Y-directions. FIGS. 16-21 show additional,particularly useful possibilities for embodiments of the milling systemaccording to the present invention.

[0051] Selection of the pattern to be milled is made by using a patternselection sheet included for each milling system. Thus, the user canobtain information concerning which pattern cutouts (examples) 4 areneeded for forming the desired pattern.

[0052] In the simplest case, the actual milling process proceeds asfollows: in the preferred embodiment of the milling system according tothe present invention, the base plate 2 is placed upon the workpiece,suitably aligned, and then locked in place by using threaded clamps, forexample. The rotatable template 3 must remain movable mobile in thiscase. The size of the tracing collar 16 and also the router bit 17 to beused are suggested on the router 11 for each pattern. Then, the cuttingdepth of the router 11 is set. Next, the router 11 equipped with tracingcollar 16 and router bit 17 is guided along the inside edges of thepattern cutouts (example) 4 belonging to the pattern in the template 3.

[0053] According to the specified cutting pattern, the movable template3 is moved into a new position after each milling process by shifting,turning, sliding or rotating. These steps are then repeated until thedesired pattern has been completely formed. For cutting particularpatterns, often only partial segments of the pattern cutouts (example) 4are needed. Based on the pattern selection sheet, the user will be ableto obtain information indicating which partial segments of the patternring of the router are to be followed. FIG. 2 and FIG. 9 show top viewsof the preferred embodiment of the milling system according to thepresent invention, with examples of pattern cutouts (examples) 4 in themovable template 3 and also a small selection (FIGS. 3-8 and FIGS.10-15) of patterns that can be cut with these templates. In the millingpatterns according to FIGS. 3-8, a guide bar 13 is used in order toexpand the milling pattern in the X- or Y-directions.

[0054] A preferred embodiment of the invention is described below.

[0055] A milling system 20 for milling patterns into the workpiece 7 isillustrated in FIGS. 22-25. The system 20 comprises a baseplate 22having an aperture 24. The system 20 further includes a template 26disposed within the aperture 24 and positionable in a plurality ofregistrated orientations relative to the baseplate 22.

[0056] Referring to FIG. 23, the baseplate 22 is formed of twoseparable, symmetrical baseplate parts 22 a. The two baseplate parts 22a each include a tongue 28 on one of the parts 22 a and a cooperativeslot 30 in the other of the parts 22 a to received the respective tongue28, for interconnecting the parts 22 a together. The tongue 28 has araised detent 28 a and the slot includes an aperture 30 a to receive thedetent 28 a.

[0057] The baseplate 22 includes twenty-four recesses 34, which aresequentially labeled A, B, C, D. The template 26 includes sixprotrusions 36, which locate the template 26 relative to the baseplate22.

[0058] The baseplate 22 includes opposing notches 38, and the template26 has a center positioning aperture 24 b for aligning the workpiece 7with the milling system 20. Additionally, the baseplate aperture 24 hasa beveled aperture surface 24 a, and the template 26 has a cooperativelybeveled outer surface 27.

[0059] The template has a plurality of pattern cut-outs 27. The template26 further has an upper surface 26 a and a lower surface 26 b. The uppersurface 26 a is flush. The lower surface 26 b has cored out segments 26c to reduce material cost. The baseplate lower surface 26 b is textured.

[0060] In order to view a resulting pattern before milling the workpiece7, a pencil guide 40, illustrated in FIG. 25a, is provided. The pencilguide 40 holds a pencil 41, or other like writing instrument. With thepencil guide 40 and the pencil 41, one can trace the pattern on theworkpiece 7. The pencil guide 40 has two diameters, to vary the distancethe pencil 41 is spaced from the walls of the pattern cutout 27, andhence varies the resulting pattern.

[0061] A preferred embodiment of a system 44 for vertically supporting arotary cutting tool 46 is illustrated in FIGS. 26-29.

[0062] The tool support system 44 comprises a transparent base 48 and athree posts 50 extending upwardly from the base 48. The base has a lowersurface 48 a having two, generally circular ribs 48 a (FIG. 29), raisedapproximately 1/20,000 of an inch. The ribs 48 a raise the base awayfrom the template 26, so as to prevent scratching of the base 48 andmaintain its transparency. The periphery of the base 48 is also beveled,to permit it to smoothly slide over surface bumps.

[0063] The system 44 further includes a tool support 52 for supportingthe rotary tool 46. The tool support 52 has a plurality of sleeves 54,one associated with each of the posts 50. Each of the sleeves 54includes first and second bushings 55 a, 55 b. The sleeves 54 slidablyreceive respective ones of the posts 50. The system still furtherincludes two springs 56 disposed in respective spring sleeves 57 forbiasing the tool support 52 away from the base 48. The springs 56 eachhave a first end 56 a disposed in the spring sleeve 57 and a second end56 b engaging the base 48.

[0064] The system 44 also includes a gauge 60 having one end 60 asecured to the tool support 52 by a set screw 61 and the other end 60 badapted to engage the base 48 for selectively limiting the travel of thetool support 52 towards the base 48, which sets the depth of cut intothe workpiece 7. The gauge is graduated, to display the selected depthof cut.

[0065] The tool support 52 includes a threaded opening 64 to receive athreaded nose 66 of the rotary tool 46. The tool support 52 alsoincludes a pair of handles 68 for permitting a user to move the toolsupport 52 relative to the base 48.

[0066] Referring to FIGS. 30 and 31, the base 48 includes a guidebushing 70 having a cylindrical nose 70 b. The diameter of thecylindrical nose 70 b determines the distance the tool bit is spacedfrom the walls of the pattern cutout 27, and hence affects the patternmilled in the workpiece 7. The diameter of the cylindrical nose 70 b isidentified by a molded indicia I (raised or depressed) on the surface ofthe guide bushing 70. The guide bushing 70 is easily removable andincludes three tapered lips 72 to receive a respective one of three lips74 on the base 48. Each of the bushing lips 72 includes a recesss 72 ato lockingly engage with a cooperating protrusion 74 a on the base lip74. A wall 75 prevents over-rotation of the guide bushing 70.Accordingly, the guide bushing 70 can readily be changed to one having adifferent nose 70 b diameter without the need for special tools. Theguide bushing 70 includes large openings 70 a for visibility and topermit grasping to rotate the bushing 70. The guide bushing 70 a furtherincludes indicia 70 c indicating the circumferential dimension of thenose 70 b.

[0067] The system 44 also includes a spring loaded release 76 forlocking the tool support 52 in a position a selected distance relativeto the base 48.

[0068] The base 48 further includes a vacuum attachment 78 to attach avacuum device (not shown) to remove cuttings through the large openings70 a in the guide bushing 70.

[0069] From the foregoing, it will be observed that numerous variationsand modifications may be effected without departing from the spirit andscope of the invention. It is to be understood that no limitation withrespect to the specific apparatus illustrated herein is intended orshould be inferred. It is, of course, intended to cover by the appendedclaims all such modifications as fall within the scope of the claims.

What is claimed is:
 1. A milling system, particularly for the milling ofsimple up to complex complementary and expandable patterns from aworkpiece (7) with a router (11) guided therewith, characterized in thatat least one recess (1) is cut in a base plate (2) and at least onemovable template (3) lockable in preset positions can fit accuratelyinto said recess.
 2. The milling system of claim 1, characterized inthat the recess for the movable template (3) can be in the form of apolygon, circle, or arc of a circle.
 3. The milling system according toclaim 1, characterized in that the movable template (3) can be dividedinto several sectors (8) and can consist of transparent material.
 4. Themilling system according to claims 1 characterized in that in themovable template (3), there is at least one recess into which insertionparts (5) can be fitted and at least one pattern recess in the insertionpart (example) (6) is cut away from the insertion parts (5).
 5. Themilling system according to claim 1 characterized in that one or moremovable templates can, in turn, be installed in the movable template(3).
 6. The milling system according to claim 1 characterized in thatthe movable templates (3) have locking mechanisms (9) (14) (15).
 7. Themilling system according to claim 1 characterized in that the positionof the movable templates (3) in the accurately fitting recess of thebase plate (2) or in the template (3) itself, can be changed byshifting, turning, sliding, and rotating, as a function of the requiredpattern to be milled after each milling step.
 8. The milling systemaccording to claim 1, characterized in that at least one pattern cutout(example) (4) on the movable template (3) is removed from a definedarea.
 9. The milling system according to claim 1, characterized in thatsecuring elements (10) for the employment of a guide bar (13), which isadjustable in the X- and Y-directions, are located on the base plate(2).
 10. The milling system according to claim 1, characterized in thatby use of a guide bar (13) adjustable in the X- and Y-directions, apattern milling expansion is possible both in the X- and Y-directions.11. The milling system according to claim 1, characterized in that themovable templates (3) for different templates may be compatible andcomplementary in order to form new patterns.
 12. The milling systemaccording to claim 1, characterized in that the pattern to be milled canbe broken down into the form of sample cutouts (example) (4) formed atprecisely defined positions in the movable template (3).
 13. A methodfor the milling of patterns from a workpiece (7) by means of the millingsystem (12) and a router (11) guided therewith, with tracing collar (16)and router bit (17), according to claim 1, characterized by thefollowing steps: specification of the pattern to be milled, or itsselection from an included pattern sheet; setting up and locking themilling system to the workpiece; selection of the pattern recesses(example) (4) belonging to the pattern of the movable template (3);adjustment of the cutting depth of the router; turning on the router(11), bringing it into position and plunging the router bit into theworkpiece; guiding the router (11) equipped with tracing collar (16) androuter bit (17) along the inner contours of the pattern cutouts(example) (4) belonging to the pattern in the template (3); switchingoff and removing the router (11); bringing the template into a newposition within the base plate (2), in accordance with the pattern,after each milling process, by shifting, turning, sliding, and rotating,as a function of pattern requirements; and repetition of steps e) to f)until the desired pattern has been cut.
 14. A milling system for millingpatterns into a workpiece, the system comprising: a baseplate having anaperture; and a template disposed within the aperture and positionablein a plurality of registrated orientations relative to the baseplate,wherein the baseplate is formed of two separable baseplate parts. 15.The milling system of claim 14 wherein the two baseplate parts aresymmetrical.
 16. The milling system of claim 14 wherein the twobaseplate parts include means for interconnecting them together.
 17. Themilling system of claim 16 wherein the interconnecting means comprises atongue on one of the parts and a cooperative slot in the other of theparts to received the tongue.
 18. The milling system of claim 17 whereinthe tongue has a raised detent and the slot includes an aperture toreceive the detent.
 19. The milling system of claim 16 wherein theinterconnecting means comprises a tongue on each of the parts and acooperative slot in each of the parts, wherein each of the slotsreceives a respective one of the tongues.
 20. The milling system ofclaim 19 wherein each of the tongues has a raised detent and each of theslots includes an aperture to receive the respective detent.
 21. Themilling system of claim 14 including means for locating the baseplaterelative to the template.
 22. The milling system of claim 21 wherein thelocating means comprise indicia on one of the baseplate or the template.23. The milling system of claim 14 wherein: the baseplate aperture has aperipheral surface and the baseplate includes a plurality of recessesdisposed about the periphery of the aperture; and the template has aprotrusion for meshing engagement with one of the recesses forpositioning the template relative to the baseplate.
 24. The millingsystem of claim 23 wherein the template has a plurality of protrusionsfor meshing engagement with respective ones of the recesses forpositioning the template relative to the baseplate.
 25. The millingsystem of claim 24 wherein the protrusions and the recesses includeindicia for rotationally positioning the template relative to thebaseplate.
 26. The milling system of claim 25 wherein the indiciacomprise a number of repeating characters.
 27. The milling system ofclaim 26 wherein the baseplate has a number of protrusions and thenumber of repeating characters is evenly dividable into the number ofprotrusions.
 28. The milling system of claim 14 wherein the baseplateincludes opposing notches for aligning the workpiece with the millingsystem.
 29. The milling system of claim 14 wherein: the baseplateaperture has a beveled aperture surface; and the template has acooperatively beveled outer surface.
 30. The milling system of claim 14wherein the template has a center positioning aperture.
 31. The millingsystem of claim 14 wherein the template has an upper surface and a lowersurface, and the upper surface is flush.
 32. The milling system of claim31 wherein the baseplate lower surface is ribbed.
 33. A system forvertically supporting a rotary cutting tool, the system comprising: abase; a plurality of posts extending upwardly from the base; a toolsupport for supporting the rotary tool, the tool support having aplurality of sleeves, one associated with each of the posts, the sleevesslidably receiving respective ones of the posts; means for biasing thetool support away from the base.
 34. The system of claim 33 includingmeans for selectively limiting the travel of the tool support towardsthe base.
 35. The system of claim 34 wherein the limiting meanscomprises a gauge having one end secured to the tool support and theother end adapted to engage the base.
 36. The system of claim 33 whereinthe biasing means comprises a spring.
 37. The system of claim 36 whereinthe tool support includes a spring sleeve, and the spring has a firstend disposed in the spring sleeve and a second end engaging the base.38. The system of claim 33 wherein the biasing means comprises aplurality of springs.
 39. The system of claim 38 wherein the toolsupport includes a plurality of spring sleeves, and each of the springshas a first end disposed in a respective one of the spring sleeves and asecond end engaging the base.
 40. The system of claim 39 wherein thetool support includes a threaded opening to receive a threaded nose ofthe rotary tool.
 41. The system of claim 33 wherein the tool supportincludes a handle for moving the tool support relative to the base. 42.The system of claim 33 wherein the tool support includes two spacedhandles for moving the tool support relative to the base.
 43. The systemof claim 33 wherein each of the sleeves includes a bushing.
 44. Thesystem of claim 33 wherein each of the sleeves includes first and secondbushings.
 45. The system of claim 33 including three of the posts and arespective three of the sleeves.
 46. The system of claim 33 wherein thebase is transparent.
 47. The system of claim 46 wherein the base has alower surface and the lower surface includes a raised rib.
 48. Thesystem of claim 47 wherein the rib is generally circular
 49. The systemof claim 33 wherein the base includes a guide bushing.
 50. The system ofclaim 49 includes means for releasably securing the guide bushing to thebase.
 51. The system of claim 50 wherein the releasably securing meanscomprises a lip on the base to receive a respective lip on the guidebushing.
 52. The system of claim 33 including means for locking the toolsupport in a position a selected distance relative to the base.
 53. Thesystem of claim 52 wherein the locking means includes a spring loadedrelease.
 54. A milling system for milling patterns into a workpiece, thesystem comprising: a baseplate having an aperture; a template disposedwithin the aperture and positionable in a plurality of registratedorientations relative to the baseplate, wherein the baseplate is formedof two separable baseplate parts; a rotary cutting tool plunger, theplunger comprising a base, a plurality of posts extending upwardly fromthe base, a tool support for supporting the rotary tool, the toolsupport having a plurality of sleeves, one associated with each of theposts, the sleeves slidably receiving respective ones of the posts; andmeans for biasing the tool support away from the base.